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DESIGN REPORT
Acton Wastewater Treatment Plant Expansion
University of Guelph Design Team:
Alexandra Chan
Adam Erb
Cynthia Mason
Julia Veerman
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
i
ACKNOWLEDGEMENTS
Respected members of the WEF Student Design Competition SubCommittee:
Thank you for considering the University of Guelph Design Team submission for the design of the Acton
Wastewater Treatment Plant Expansion. Enclosed is our final design report.
We would like to express our utmost gratitude to the following individuals for their support and
assistance throughout the duration of this project:
Dr. Hongde Zhou, P.Eng. - Faculty Advisor
Professor of the School of Engineering University of Guelph
Dave Arsenault, P.Eng. - Consultant Advisor
Project Manager CH2M Hill, Water Business Group
Rafiq Qutub, P.Eng.
Student Design Competition Sub-Committee Chair Water Environment Association of Ontario
Lauren Zuravnsky, P.E.
Design Competition Sub-Committee Chair Water Environment Federation
Please contact us if you require any further information on this project. We appreciate the time, effort,
and consideration you have given us.
Sincerely,
University of Guelph Design Team:
Alexandra Chan
Adam Erb
Cynthia Mason
Julia Veerman
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
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ATTRIBUTION TABLE
Section Adam Alexandra Cynthia Julia
REPORT BODY
Abstract X
Nomenclature X
Introduction X
Process Selection X
Phase 1 Facility Design X X X
Phase 2 Facility Design X
Process Control and Instrumentation X
Construction Staging X X
Economic Evaluation X X
Innovation X
Health and Safety X
Conclusions and Recommendations X
APPENDIX
Drawings X X X X
Interim Report X X X X
Assumptions X X X X
Process Control and Instrumentation X
Modeling X
Cost Estimate X X X
Manufacturer Specification Sheets X
Design Calculations X X X
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
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ABSTRACT
The Regional Municipality of Halton has identified the need to increase the capacity of the Acton WTTP
in two phases to accommodate their population growth projections. A review of the existing facility and
process selection methodology, proposed layout, design of treatment processes, controls and
instrumentation, hydraulic profile evaluation, population analysis, and economic analysis are provided
as part of the Phase 1 preliminary design. The Phase 2 conceptual design includes the layout, scaled
design of treatment processes and controls and instrumentation, and economic evaluation.
The recommended retrofit for Phase 1 is to expand the number of treatment trains for clarification,
disinfection, and anaerobic digestion, and include PFR conventional activated sludge basins with
nitrification, deep bed filter, and belt press. Upgrades will be made to the SCADA, automation, and
electrical system to facilitate the retrofit. The conceptual design includes an additional train for
clarification, filtration and disinfection, and a retrofit of the existing aeration basins to PFR with BNR.
The capital cost for the Phase 1 expansion is estimated at $24M with annual O&M costs of $1.2M, and
the capital cost estimation for the Phase 2 expansion is $12M. The Phase 1 implementation and
construction is expected to last 24 months.
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
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NOMENCLATURE
BOD Biochemical Oxygen Demand
BNR Biological Nutrient Removal
C of A Certificate of Approval
CH4 Methane
CMMS Computerized Maintenance Management Systems
CN2 Advanced carbon-nitrogen
CNP Carbon-nitrogen-phosphorus
CVC Credit Valley Conservation Authority
CSTR Continuous Stir Tank Reactor
DO Dissolved oxygen
EA Environmental Assessment
F/M Food to microorganism
HRT Hydraulic Retention Time
HVAC Heating, Ventilation and Air Conditioning
IED Intelligent Electronic Devices
LP/HI Low pressure/high intensity
LP/LI Low pressure/low intensity
MLSS Mixed liquor suspended solids
MOE Ministry of the Environment
MP/HI Medium pressure/high intensity
NO2 Nitrite
NO3 Nitrate
O&M Operations and maintenance
P&ID Process and instrumentation diagram
PC Personal Computer
PFD Process flow diagram
PFR Plug Flow Reactor
PLC Programmable Logic Controller
RAS Return Activated Sludge
RTU Remote Terminal Unit
SCADA Supervisory control and data acquisition
SRT Solids retention time
TP Total phosphorus
TSS Total suspended solids
US EPA United States Environmental Protection Agency
UV Ultraviolet
WEAO Water Environment Association of Ontario
WWTP Wastewater Treatment Plant
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TABLE OF CONTENTS
ACKNOWLEDGEMENTS .................................................................................................................................. i
ATTRIBUTION TABLE ..................................................................................................................................... ii
ABSTRACT ..................................................................................................................................................... iii
NOMENCLATURE .......................................................................................................................................... iv
1 INTRODUCTION .................................................................................................................................... 1
Scope of Work .......................................................................................................................................... 1
Design Basis .............................................................................................................................................. 2
2 PROCESS SELECTION ............................................................................................................................. 3
3 PHASE 1 FACILITY DESIGN .................................................................................................................... 3
3.1 Wastewater Receiving Station and Headworks .......................................................................... 3
3.2 Primary Clarification .................................................................................................................... 3
3.3 Secondary Treatment .................................................................................................................. 4
3.4 Secondary Clarification ................................................................................................................ 4
3.5 Tertiary Treatment for Phosphorus Removal .............................................................................. 5
3.5.1 Chemical Addition ................................................................................................................... 5
3.5.2 Filtration .................................................................................................................................. 5
3.6 Disinfection System ..................................................................................................................... 6
3.7 Sludge Digestion .......................................................................................................................... 7
3.8 Gravity Belt Press ......................................................................................................................... 8
3.9 Sludge Disposal ............................................................................................................................ 8
3.10 Noise and Odour Control ............................................................................................................. 8
3.11 Hydraulic Profile .......................................................................................................................... 8
3.12 Electrical Upgrades ...................................................................................................................... 9
3.13 Modeling ...................................................................................................................................... 9
4 PHASE 2 FACILITY DESIGN .................................................................................................................... 9
5 PROCESS CONTROL AND INSTRUMENTATION ................................................................................... 10
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5.1 Online Sampling and Control ..................................................................................................... 10
5.2 Manual Grab Sampling .............................................................................................................. 11
6 CONSTRUCTION STAGING .................................................................................................................. 12
6.1 Construction Schedule ............................................................................................................... 12
6.2 Environmental Considerations .................................................................................................. 13
7 ECONOMIC EVALUATION ................................................................................................................... 15
7.1 Capital Cost ................................................................................................................................ 15
7.2 Operations and Maintenance .................................................................................................... 16
8 INNOVATION ...................................................................................................................................... 17
9 HEALTH AND SAFETY .......................................................................................................................... 17
9.1 Engineering Design .................................................................................................................... 17
9.2 Facility Security .......................................................................................................................... 17
9.3 Training ...................................................................................................................................... 17
9.4 Laboratory ................................................................................................................................. 17
9.5 Construction .............................................................................................................................. 17
10 CONCLUSIONS AND RECOMMENDATIONS ........................................................................................ 18
11 REFERENCES ....................................................................................................................................... 19
APPENDIX A DRAWINGS ........................................................................................................................... 22
APPENDIX B INTERIM REPORT ................................................................................................................. 23
APPENDIX C - PROCESS CONTROL AND INSTRUMENTATION ..................................................................... 41
APPENDIX D MODELING ........................................................................................................................... 46
APPENDIX E - COST ESTIMATE .................................................................................................................... 52
APPENDIX F MANUFACTURER SPECIFICATION SHEETS ........................................................................... 61
APPENDIX G DESIGN CALCULATIONS ....................................................................................................... 69
LIST OF TABLES
Table 1: Existing and Proposed Acton WWTP Hydraulic Loading ................................................................. 2
Table 2: Design Basis for Annual Average Pollutant Loading........................................................................ 2
Table 3: Existing and Proposed Acton WWTP Effluents Objectives and Limits ............................................ 2
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Table 4: Primary Clarifier Design ................................................................................................................... 3
Table 5: Removal Rates of Primary Clarifier ................................................................................................. 4
Table 6: Design Summary for Each New Aeration Tank ............................................................................... 4
Table 7: Secondary Clarifier Design Summary .............................................................................................. 5
Table 8: Alum Dosing Design Summary Table .............................................................................................. 5
Table 9: Dual Media Deep Bed Filtration Design Summary Table ................................................................ 5
Table 10: UV Design Summarization ............................................................................................................. 6
Table 11: Anaerobic Digestion Design Summary (at MDF) ........................................................................... 7
Table 12: Belt Press Summary ....................................................................................................................... 8
Table 13: Phase 2 Conceptual Design with respect to Phase 1 Design ....................................................... 10
Table 14: SCADA Monitoring Summary ...................................................................................................... 11
Table 15: Grab Sample Testing ................................................................................................................... 12
Table 16: Construction Summary ................................................................................................................ 12
Table 17: Population Growth Estimate ....................................................................................................... 24
Table 18: Calculated Flow Rate Estimates .................................................................................................. 25
Table 19: MOE Design Criteria for Primary Sedimentation Tanks .............................................................. 31
Table 20: MOE Design Criteria for Activated-Sludge Aeration Tanks (MOE, 2008). ................................... 32
Table 21: MOE Design Criteria for Secondary Sedimentation Tanks .......................................................... 32
Table 22: Sources of Solid Wastes from Facility ......................................................................................... 33
Table 23: Types of Solids ............................................................................................................................. 33
Table 24: MOE Design Guidelines for Digesters ......................................................................................... 34
Table 25: Comparison of Different Lamp Types ......................................................................................... 35
Table 26: Gravity Belt Press Design Considerations ................................................................................... 36
Table 27: Biological Treatment Decision Matrix ......................................................................................... 37
Table 28: Sludge Dewatering Decision Matrix ............................................................................................ 38
Table 29: Sludge Disposal Decision Matrix ................................................................................................. 38
Table 30: Phosphorus Removal Decision Matrix ........................................................................................ 39
Table 31: SCADA Decision Matrix ............................................................................................................... 40
Table 32: Regular Maintenance .................................................................................................................. 45
Table 33: Model Design Basis ..................................................................................................................... 47
Table 34: Model Dynamics Equations for Primary Process ........................................................................ 47
Table 35: Model Dynamics Equations for Secondary Process .................................................................... 49
Table 36: Model Results in Comparison to Proposed Effluent Objectives and Limits ................................ 51
Table 37: Major Equipment Cost Summary for Phase 1 ............................................................................. 53
Table 38: Concrete Cost Summary for Phase 1 ........................................................................................... 54
Table 39: Control and Instrumentation Cost Summary for Phase 1 ........................................................... 56
Table 40: Project Capital Cost Summary for Phase 1 Expansion ................................................................ 58
Table 41: Project Capital Cost Summary for Phase 2 Expansion ................................................................ 59
LIST OF FIGURES
Figure 1: Location of the Acton WWTP (Generated by Google Maps) ......................................................... 1
Figure 2: GANTT Chart for Construction Schedule...................................................................................... 15
Figure 3: Phase 1 Project Capital Cost Estimate (Cost in Million (CAD)) ..................................................... 15
Figure 4: Phase 2 Project Capital Cost Estimate (Cost in Million (CAD)) ..................................................... 16
Figure 5: Annual Phase 1 O&M Cost Estimate (Cost in 10K (CAD)) ............................................................ 16
Figure 6: Activated Sludge Process Control ................................................................................................ 43
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Figure 7: STOAT
schematic ....................................................................................................................... 50
Figure 8: Model Outputs ............................................................................................................................. 51
Figure 9: Hindered settling Solids Flux Curve used for Secondary Clarifier Sizing ...................................... 71
Figure 10: Plant B Alum Dose Determination ............................................................................................. 72
LIST OF DRAWINGS
Drawing 1: Phase 1 Expansion Plant Layout
Drawing 2: Phase 1 PFD
Drawing 3: Primary Clarifier
Drawing 4: Aeration Basin
Drawing 5: Secondary Clarifier
Drawing 6: Deep Bed Dual Media Filter
Drawing 7: UV Disinfection Channel
Drawing 8: Anaerobic Dual-Stage Digester
Drawing 9a: Phase 1 P&ID Primary Treatment
Drawing 9b: Phase 1 P&ID Secondary Treatment
Drawing 9c: Phase 1 P&ID Tertiary Treatment
Drawing 9d: Phase 1 P&ID Sludge Treatment
Drawing 10: Hydraulic Profile
Drawing 11: Phase 2 Expansion Plant Layout
Drawing 12: Phase 2 PFD
Drawing 13: Phase 2 P&ID Changes
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
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1 INTRODUCTION
This report evaluates design alternatives for the proposed expansion of the Acton Wastewater
Treatment Plant (WWTP) (Figure 1). The Regional Municipality of Halton (Halton Region) has identified
the need to increase the existing WWTP rated capacity as it is currently operating near peak capacity. Its
capacity must be expanded to accommodate the projected future growth in two phases: Phase 1 by
2021, and Phase 2 by 2031 (Regional Municipality of Halton, 2009). The expansion is designed to meet
the projected flows and effluent criteria, and is based on the Class Environmental Assessment (EA)
completed in 2010. The objectives of this report are to:
Provide a preliminary design and layout for Phase 1 (5 600 m
3
/day to meet capacity demand to
2021; and
Develop a conceptual layout for Phase 2 (7 000 m
3
/day) expansion to meet the ultimate capacity
requirement in 2031 and beyond.
Figure 1: Location of the Acton WWTP (Generated by Google Maps)
Scope of Work
The scope of this design project includes:
Expansion of the existing inlet works;
Expansion of the biological treatment processes (secondary and tertiary treatment);
Expansion of the effluent UV disinfection facility;
Expansion of the anaerobic handling facility (biosolids are shipped off site);
Expansion of electrical and standby power facilities; and
Upgrades to the instrumentation and SCADA system.
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Design Basis
The projected design flows and effluent criteria provided by Halton Region were used for as a design
basis. A population analysis was conducted to verify the projected flows (see Appendix B). Table 1
shows the hydraulic loading for the existing plant and Phase 1 and 2 expansions. Table 2 shows the
average and maximum raw pollutant loading obtained from 2009-2010 data from the Acton WWTP.
The Acton WWTP discharges its effluent into Black Creek, which is under the jurisdiction of the Credit
Valley Conservation Authority (CVC). It is classified as a cold-water fishery and therefore is sensitive to
temperature change and contaminant loads. Table 3 shows the existing and projected effluent limits
and objectives, which are based on the average of monthly concentration data, excepting un-ionized
ammonia nitrogen that is based on a single sample.
The plant expansion will provide an increase in the level of treatment provided in addition to the
hydraulic capacity, in keeping with reliable, economically and environmentally sustainable technologies.
Table 1: Existing and Proposed Acton WWTP Hydraulic Loading
Parameter Current
(2008)
(m
3
/day)
Phase 1 Given
(m
3
/day)
Phase 2 Given
(m
3
/day)
Average Daily Flow (dry weather) 4610 5600 7000
Maximum Daily Flow (dry weather) 6160 9690 14307
Instantaneous Peak Flow (wet weather) 15980 14955 21452
Table 2: Design Basis for Annual Average Pollutant Loading
Parameter Annual Average
Concentration (mg/L)
Maximum Monthly
Concentration (mg/L)
BOD
5
165 220
TSS 191 238
Total Phosphorus 4.87 5.94
Ammonia + Ammonium 24.4 30.0
TKN 36.0 44.7
Table 3: Existing and Proposed Acton WWTP Effluents Objectives and Limits
Parameter Current Certificate
of Approval
Proposed Effluent
Objective/Limit
BOD
5
(mg/L) 2/5 2/5
TSS (mg/L) 3/5 3/5
Total Phosphorus (mg/L) 0.2/0.3 0.1/0.2
(Ammonia + Ammonium) Nitrogen (mg/L)
Non-freezing period (May 1 to Nov 31)
Freezing period (Dec 1 to April 30)
1.0/2.0
1.0/4.0
1.0/2.0
1.0/4.0
Unionized Ammonia (monthly average) (mg/L)
Unionized Ammonia (any single sample) (mg/L)
-
-/0.1
-/0.016
-/0.08
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Parameter Current Certificate
of Approval
Proposed Effluent
Objective/Limit
Escherichia Coli (monthly geometric mean
density) (#of organisms/100mL)
100/150 100/150
2 PROCESS SELECTION
Process selection for the Acton WWTP involved the evaluation of alternative treatment processes. The
existing plant is expanded with a new layout and new technologies to accommodate increased flows and
more stringent limits for Phase 1. In Phase 2 the plant capacity is further increased to handle the
additional flows. The process selection methodology involved researching design alternatives provided
in the Project Statement and evaluating them based on relevant constraints and criteria (Appendix B).
This report focuses on the selected components and their integration for Phase 1 and Phase 2
expansion. The appendices offer supplemental information to the decision component of process
selection.
3 PHASE 1 FACILITY DESIGN
The following components have been sized based on design calculations and industry, government
guidelines and standards, and manufacturer specifications. The layout and process flow diagram (PFD)
can be seen in Drawings 1 and 2 respectively in Appendix A. All other process basin drawings can be
seen in Appendix A and design calculations in Appendix G.
3.1 Wastewater Receiving Station and Headworks
The headworks expansion has been provided by Dillon Consulting (Dillon Consulting, 2008). No changes
have been made to this design. Bar screens and a vortex grit chamber are included in this design.
3.2 Primary Clarification
The total volume of the primary clarifiers is 843 m
3
. The volume will be divided into four rectangular
clarifiers: two existing in Plant B at 165 m
3
and two new at 256 m
3
. This accommodates the incoming
flow from the grit chamber and recirculated water flow from the digester and belt press. Table 4 and
Table 5 summarize the primary clarifier design and expected performance.
Table 4: Primary Clarifier Design
Parameter MDF ADF
Total Volume 843 m
3
Number of Clarifiers 4
Volume of Ex. Clarifiers 165 m
3
Volume of New Clarifiers 256 m
3
Ex. Dimensions (L:W:D)
From Google Earth
13.5 m : 3.5 m : 3.5 m
New Dimensions (L:W:D) 16 m : 4 m : 4 m
New L:W ratio 4
New W:D ratio 1
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Parameter MDF ADF
New Weir Length 4 m
Pump Capacity 2 m
3
/day
HRT 2 hours 3.5 hours
Overflow Rate 27.5 m
3
/ m
2
/day 50 m
3
/ m
2
/day
TSS Removal 62.5% (3317 kg/day) 40.3% (917 kg/day)
BOD Removal 35.1% (735 kg/day) 57.1% (425 kg/day)
Table 5: Removal Rates of Primary Clarifier
Parameter In (mg/L) MDF % reduction Out (mg/L)
TSS 600 35.1 225
BOD 216 57.1 129
3.3 Secondary Treatment
A conventional plug flow activated-sludge system with nitrification will be the preferred secondary
treatment process for the Phase 1 expansion. This suspended growth biological treatment process
consists of a baffled wall configuration, such that space utilization can be optimized. The activated-
sludge has been designed for maximum daily flow with additional flow feedback, accomodating a total
flow of 9872 m
3
/d. The existing Plant B activated sludge systems will be used in parallel to the proposed
Phase 1 expansion, providing an additional 1275 m
3
/d required for sufficient treatment; therefore, only
2 additional clarifiers will be required. The design summary for each proposed clarifier is outlined in
Table 6 below.
Table 6: Design Summary for Each New Aeration Tank
Parameter Design Flow
Volume (m
3
) 638 m
3
HRT (h) 4.6 h
SRT (d) 12 d
Sludge Production 970 kg/d
Average RAS Flow-rate 182 m
3
/d
Target MLSS 4000 mg/L
Average DO 2 mg/L
3.4 Secondary Clarification
The secondary clarifiers were designed using the Solids Flux Analysis approach. Following the execution
of this method, it was concluded that two additional sedimentation tanks would be required to handle
future design flows, in addition to the existing tanks in Plant B. The required sizing parameters for these
supplementary tanks are outlined below in Table 7. These clarifiers were sized using the maximum daily
flow (9690 m
3
/d) as the design flow. The mixed liquor suspended solids concentration (MLSS)
corresponding to the parameters of this system was found to be 6620 mg/L, provided that the overflow
rate is sufficient. The sizing of the clarifiers ensure that should one tank need to be taken out of service
for maintenance, the rest of the plant can still function. This system will utilize the Envirex Chain &
Scraper Sludge Collector System for sludge removal. Table 7 summarizes the relevant sizing information.
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Table 7: Secondary Clarifier Design Summary
Parameter Design Flow
Total Volume (m
3
) 862
Number of Clarifiers 2
Volume per Clarifier (m
3
) 431
Dimensions (m), L : W : D 22 : 4.9 : 4
HRT (h) 3
Overflow Rate (m
3
/m
2
d) 31
Solids Loading (kg/m
2
d) 12
Pump Capacity (m
3
/day) 72
3.5 Tertiary Treatment for Phosphorus Removal
Chemical addition in the secondary process and adding a deep bed filtration system will assist the facility
in meeting the required phosphorus objectives.
3.5.1 Chemical Addition
Alum will be added near the end of the aeration basin, in a similar manner as the existing design. It is
assumed that the WWTP currently uses liquid alum as opposed to dry alum as this is the less expensive,
more common form of alum (Arsenault, 2011). The dosage for alum was determined based on the
Acton WWTP 2009-2010 concentration data, but pilot tests must be conducted to determine the
required operational dosage. A summary of the alum dosing system is shown in Table 8.
Table 8: Alum Dosing Design Summary Table
Parameter Value
Dosage 85 mg/L
Purity 45%
Amount of Pure Alum Required 824 kg/d
Alum Consumption Rate 1.4 m
3
/d
Storage Tank Volume x 2 9.5 m
3
Solution Tank Volume 1.01 m
3
Feeder Pump Capacity 0.04 m
3
/h (1 operational, 1 redundant)
Dosing Pump Capacity 0.03 m
3
/h (1 operational, 1 redundant)
Mixer Power Required 19 W
3.5.2 Filtration
It is proposed that the existing filtration system be expanded to include a third train with a deep bed
dual media filter. The media selected are sand and anthracite. A summary of the proposed filtration
system is in Table 9.
Table 9: Dual Media Deep Bed Filtration Design Summary Table
Parameter Value
Design Flow Rate 5070 m
3
/d
Surface Loading Rate 7.2 m
3
/m
2
h
Filter Media Dimensions (L:W:D) 8 m x 4 m x 1.2 m
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Parameter Value
Anthracite
Effective Size
Specific Gravity
Porosity
Depth
1.2 mm
1.7
0.56
46 cm
Sand
Effective Size
Specific Gravity
Porosity
Depth
0.65 mm
2.65
0.43
74 cm
Design Head Loss 1.6 m
Backwash Velocity 38.6 m/h
Backwash Tank Capacity 149.1 m
3
Backwash Tank Height 2.5 m
Backwash Pump Capacity 1.2 m
3
/min (2 pumps in parallel, 1 redundant)
The flow to this filter is based on the assumption that the existing filters have been designed to handle
75% of the current plant flow each, and thus the filter is only designed to handle the additional flow.
The filter operation is declining rate gravity filtration. The filtered effluent is pumped to the backwash
tank via a variable speed pump or into a clear well once the backwash tank is full. The selected
underdrain system is the Leopold Type S Technology Underdrain, which provides a uniform
distribution of air and water for backwashing.
The backwash cycle must last for a minimum of 10 minutes and achieve a minimum of 20% fluidized bed
expansion (MOE, 2008). During backwashing, filter is removed from operation and the water level in the
filter is lowered to approximately 10 cm. Air scour and surface wash via rotating nozzles then begins for
approximately 5 minutes. The last minute is overlapped by backwashing, which continues for an
additional 7 minutes. The water and freed particles overflow into the wash trough and are sent to the
digester. Pilot tests must be conducted to determine the optimal time between backwash cycles.
The filter must be housed to maintain the air temperature. The building must house the filter electrical
equipment, heating, ventilation and air conditioning (HVAC) system, and a PLC.
3.6 Disinfection System
The ultraviolet (UV) disinfection system will be expanded to treat the new peak flow. The Trojan
UV3000PLUS has been selected for this design, which has the capability and air convection cooling of
the ballasts (Trojan Technologies, 2009). Trojan Technologies is also a world leader in providing reliable
UV systems and is locally-based. The Trojan UV3000PLUS brochure is provided in Appendix F. Table 10
shows the preliminary design of the UV disinfection system.
Table 10: UV Design Summarization
Parameter Value
UV Dose 40 mJ/cm
2
at peak daily flow at end of lamp life
Channel Dimensions (L:W:D) 14.5 m x 0.4 m x 0.8 m
Number of Channels 2
Number of Banks/Channel 3 (2 operational, 1 redundant)
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Parameter Value
Number of Modules/Bank 4
Number of Lamps/Module 8
Total Number of Lamps/Channel 96
Power Requirement/Channel 40 kW (250W/lamp with 40% efficiency)
Hydraulic Design 0.65 m across channel
Level Controller Automatic level controller
Guaranteed Lamp Life (hours of actual
operation)
12 000 hours
Control of UV Dose Delivery Automatic and continuous dose posing
Cleaning Mechanism Automated mechanical/chemical cleaning
The UV systems influent water comes from the clear well via gravity flow. As this water passes through
tertiary treatment, it is expected that the water will be of low enough turbidity that lamp fouling will be
minimal. To handle the projected Phase 1 flow, three channels are required. From the site visit, it was
determined that Acton already has one operational UV channel. The modular design of the expanded
UV channels is expected to work concurrently in parallel with the existing channel. The third bank in
each channel is provided for redundancy if any of the banks need to be taken out of operation. As three
channels exist, it was determined that a redundant channel was not required. Each channel has the
capacity to treat 4000 L/min, and is equipped with a baffle for even flow distribution.
The UV channel will be housed alongside the existing UV channel. The required equipment and
instrumentation include the UV electrical equipment, process logic controllers (PLC), and HVAC
equipment. It has been assumed that the existing UV area has enough space for additional storage of
replacement parts (i.e. lamps, ballasts, cleaning solution) and other UV equipment (i.e. hoist).
3.7 Sludge Digestion
The dual-stage anaerobic digestion process will remain the same for stabilizing sludge. A new series of
digesters will be built to operate in parallel with the existing digester. The first digester holds the
hydrolysis and acidogenesis phases and then the sludge flows to the second digester that holds the
methanogenic phase. The first digester has a floating roof and the second digester has a fixed roof to
allow for methane collection. Table 11 shows the design dimensions of the dual-stage digesters.
Sludge dewatering will take place after the digested solids come from the second digesters. No sludge
thickening process has been added to the facility before the digesters.
Table 11: Anaerobic Digestion Design Summary (at MDF)
Factor Value
Digester 1 Dimensions (Diameter x Depth) 7 m x 5 m
Digester 2 Dimensions (Diameter x Depth) 11.5 m x 7 m
SRT for Digester 1 2 days
SRT for Digester 2 8 days
Influent Sludge Flow 176 m
3
/day
Sludge Flow to Belt Press 100 m
3
/day
Supernatant Flow to Primary Treatment 82 m
3
/day
Supernatant Solids Concentration 2%
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3.8 Gravity Belt Press
Currently, sludge is occasionally dewatered in drying bed, but is typically shipped off-site to a biosolids
handling facility prior to land application without drying. To be able to accommodate future flow and
population growth in Phase 1 and Phase 2, a sludge dewatering system is recommended. A belt press is
the preferred method to include because of its low cost, ease of operation and effectiveness in
separating water from the sludge, relative to using the existing sludge drying beds (see Appendix F).
Table 12 shows the design summary for the DYNA 1000A Belt Press.
Table 12: Belt Press Summary
Factor Value
Base Footprint (Length : Width) 5.34 m : 1.85 m
Belt Width 1 m
Cake Solids (estimated) 25%
Sludge Cake Flow Rate at Max Flow 4946 L/d
Filtrate Return at Max Flow 94280 L/d
Polymer Addition to Flow 3 g/kg
3.9 Sludge Disposal
In keeping with Haltons Regional Biosolids Recycling Program, the digested and thickened solids will be
sent off-site for storage and agricultural land application.
3.10 Noise and Odour Control
There are no documented issues with noise and odour control (Regional Munipality of Halton, 2008).
Potential sources of noise and odour have been acknowledged and preventative measures have been
implemented where necessary. The retrofit area is located within the WWTPs current property
boundaries, thus the existing buffer zone is maintained. There are no Ontario guidelines dictating the
required buffer zone.
The largest concern for odour is typically found in the grit chamber. Dillon Consulting has recommended
heavy duty washers/compacters to wash out organic matter and press out water, installing a grit
washer/classifier and installing a screening washer/compactor with high cleaning efficiency. It was also
recommended to designate a room in the inlet works to accommodate odour control equipment (Dillon
Consulting, 2008).
The generator is typically the noisiest part of the facility. The generator is only used for back up, so this
should only cause concern in emergencies. Should noise be of concern we recommend housing the
generator; however this design does not include a housing unit. The belt press will also be housed to
avoid noise and odour concerns. Because the buffer zone is fairly similar and relatively no new
technologies are being implemented, no other noise concerns are generated.
3.11 Hydraulic Profile
The hydraulic profile for the Phase 1 expansion is shown in Appendix A. It was a key consideration in the
proposed plant layout. The profile extends from the beginning of primary clarifier and ends at the
existing plant outfall.
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
9
3.12 Electrical Upgrades
To determine additional power requirements in the Acton WWTP upgrade, the additional projected
design treatment volume and standard treatment power requirements, were used to determine the
upgrades required. Based on the expansion requirements it was estimated that plant power
requirements would increase by only 100kW, and that additional infrastructure would be required to
support these increased power requirements.
For standby purposes, it is recommended that a generator (i.e. Caterpillar 150kW 60Hz three-phase
Diesel generator or equivalent) be purchased for use in combination with current electric backup
facilities. Additionally, power distribution infrastructure including transformers, motor control centers,
wiring, lighting, and lighting protection facilities will also be required in the plant upgrade.
3.13 Modeling
The Phase 1 primary and secondary design was modeled using STOAT. Initial simulation results suggest
that the design will enable the WWTP to meet the new effluent objectives, with the exception of MLSS
as further detailed in Appendix D. The model therefore shows the necessity of tertiary treatment.
4 PHASE 2 FACILITY DESIGN
This section describes the conceptual design for the Phase 2 expansion. Any component of the system
not described in this section should be assumed to stay the same. These retrofits anticipate the
projected Phase 2 flow and more stringent effluent limits and objectives in the future. Drawings for the
Phase 2 design can be seen in Appendix A. A summary of the Phase 2 additions with respect to Phase 1
design is provided in Table 13.
An additional primary clarifier tank of the same size as the Phase 1 new tanks, 17m by 4 m by 3.5 m, will
be built to handle the excess flow.
The aeration tanks in Plant B will be retrofitted as a plug flow reactor (PFR), in the same fashion as the
new tank built for the Phase 1 expansion. Further, biological nutrient removal (BNR) technology will be
incorporated through the addition of an anoxic and anaerobic zone, in addition an aerobic zone. The
volume of aeration tanks will be increased from 634 m
3
to 916 m
3
to hold the additional flow. This
construction will require Plant B to be removed from operation during the construction, so all flow will
be directed from the primary clarifiers to the Phase 1 aeration tanks. For this reason, no new retrofits
will be done to these tanks for Phase 2 construction. In anticipation of more stringent effluent limits, all
aeration tanks should be retrofitted to also have BNR technology in retrofits beyond Phase 2.
The filtration process in Phase 2 will depend on market conditions. If membrane technologies become
more affordable, it is recommended that this technology be incorporated in the existing system. If
membrane technologies remain expensive and operation information remains largely untested at a full
plant scale, only an additional deep bed filter will be built to accommodate the increased Phase 2 flows.
A UV channel of the same size will be added for the Phase 2 expansion.
The current digester system for Phase 1 will stay in commission. To further Actons monetary return and
sustainability, it is recommended that phosphorus recovery through struvite formation be investigated.
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
10
This will become increasingly important as natural phosphorus deposits deplete and phosphorus
demand increases.
The electrical system will be upgraded to accommodate new retrofits. Due to the unpredictability of
technological trends and advancements, no recommendations for the automation systems upgrade can
be provided at this time.
Table 13: Phase 2 Conceptual Design with respect to Phase 1 Design
Component Phase 2 Design
Wastewater Receiving Station and
Headworks
Not considered at this point due to Phase 1 design
provided by Dillon Consulting
Primary Clarification 1 additional, 17m : 4 m : 3.5 m
Secondary Treatment Plant B retrofitted as PFR, no new construction
Secondary Clarification No changes
Tertiary Treatment for Phosphorus
Removal
1 additional deep bed filter, any additional new
technology will depend on market conditions.
Disinfection System 1 additional UV channel, 14.5 m x 0.4 m x 0.8 m
Sludge Digestion Recommend investigation of phosphorus recovery via
struvite formation
Electrical Upgrades No changes
5 PROCESS CONTROL AND INSTRUMENTATION
5.1 Online Sampling and Control
To properly monitor and control the additions to the Acton WWTP, instrumentation and control
strategies will also have to be considered in the final design. These automations should be considered
seriously as large portions of a plants operating costs can be attributed to poor efficiency in plant
control strategies, or complete lack of control strategies. In evaluating instrumentation and control
options, current plant infrastructure and Supervisory Control And Data Acquisition (SCADA) hierarchy
will have to be considered for the purposes of final design. Standard SCADA components are:
Programmable Logic Controllers (PLC): robust and stable controller, based on relay-logic, and
capable of monitoring thousands of inputs and outputs.
Remote Terminal Units (RTU): an industrial grade microcontroller, often used in SCADA
networking and control.
Intelligent Electronic Devices (IED): a pre-packaged control and monitoring device. Generally
more expensive but works out of the box.
Personal Computer (PC): commonly used as a centralized process monitoring station for all plant
processes.
In the design of the instrumentation and control schemes for the plant, a distributed control system was
chosen for the processes outlined in Appendix C. Distributed control is generally more stable and
reliable than centralized control in an industrial context (Bailey and Wright, 2003). In contrast to a
centralized control scheme where a central control unit monitors and controls all processes, a
distributed control scheme generally assigns a single process to an individual onsite PLC, RTU or IED. The
onsite controller maintains crucial process control, and reports back to the SCADA system. The
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
11
advantage to this hierarchy is a reduced chance of mass failure since control is distributed across
multiple devices, and each device is in close proximity with the process of interest.
The Acton WWTP expansion will require additional PLCs, MTUs, and instrumentation to extend the
current SCADA network, and maintain efficiency in the expanded areas. The current Acton SCADA
system uses the WonderWare
produced
by the WRc. The model was constructed using sizing values determined by the design phase,
and the input parameters were characterized by the present Acton influent properties provided,
and the desired flow rates for the phase1 expansion (Table 33). Additionally, to observe the
effects of dynamic load changes on the model, each of these parameters were varied by
sinusoidal inputs, with the design values below being the average.
Table 33: Model Design Basis
Influent Parameter Unit Amount
Influent Av m
3
/d 5600
Influent Max m
3
/d 9690
BOD inflow mg/L 220
TSS inflow mg/L 239
NH
3
mg/L 20
TP mg/L 4
The STOAT
model was created using the final parameters of the plant determined for Phase 1.
This model was simplified to look only at the main wastewater train, and not to address solids
stabilization and disposal concerns in the plant. For this reason the anaerobic digestion phase
was not included in the design, and instead primary sedimentation, activated sludge, and
secondary sedimentation processes were considered.
For the primary clarifier the STOAT
model was simplified to contain only these three processes in the plant layout.
This simplification was made so that focus on the BOD removal process could be primarily
addressed. Sludge wasting and phosphorus treatment were not considered in this model. The
STOAT
schematic
Initial results of the simulation suggest that the final design parameters of the expansion are
sufficient to meet effluent quality requirements, in terms of BOD and ammonia requirements
for the project (see Figure 8). An important result to note which ties into some of the
assumptions made prior is that MLSS is above the required effluent limits in this simulation. This
result is correct, but only demonstrates water quality post-secondary clarifier, and the model
does not consider any filtration process. For this reason the elevated MLSS is addressed in the
plant design. Final steady state values in the simulation show 1.5mg/L in total BOD, 0.1mg/L in
total ammonia, and 14mg/L in suspended solids.
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Figure 8: Model Outputs
Table 36 shows how the modeling results in comparison to the proposed effluent limits and
objectives.
Table 36: Model Results in Comparison to Proposed Effluent Objectives and Limits
Parameter Objective Limit Model
BOD
5
2 mg/l 5 mg/l 1.5 mg/l
TSS 3 mg/l 5 mg/l 14 mg/l pre-filtration.
Predicted to meet
objective with
filtration introduced
to model.
Ammonia 1 mg/l 2 mg/l (non-freezing)
4 mg/l (freezing)
0.1 mg/l
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
APPENDIX E - COST ESTIMATE
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
E.1 Capital Investment
The total project cost estimate was prepared through research of generic pricing for various
WWTP components, information provided by our consultant advisor, and typical cost multipliers
provided in standard texts and in reports from other WWTPs. A preliminary estimate of major
equipment costs can be seen in Table 37. Concrete costs are shown in
Table 38. Control and instrumentation costs are shown in Table 39. Total project costs are
shown in
Table 40 with a project percentage breakdown.
Table 37: Major Equipment Cost Summary for Phase 1
Primary Clarifier
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Chain and
Flight
Sigma Plus Flights
1 Envirex 80000 50000 0 80000
Sludge Pump
Peristaltic PD
Pump 4 Watson-Marlow Brendal 8000 32000 0 32000
Troughs Troughs 6 Enviroquip 10000 60000 0 60000
Weir plates
V-notch weir
plates 12 Enviroquip 10000 120000 0.5 126000
Totals 298000
Aeration Tank
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Aeration Fine
Bubble Disc
Diffusers
Stanford 9 Disc
AFD270
Stamford Scientific
International
60000 0 60000
Total 60000
Secondary Clarifier
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Chain and
Flight
Sigma Plus Flights
1 Envirex 70000 50000 0 70000
Sludge Pump
Peristaltic PD
Pump 4 Watson-Marlow Brendal 8000 32000 0 32000
Troughs Troughs 6 Enviroquip 10000 60000 0 60000
Weir plates
V-notch weir
plates 12 Enviroquip 10000 120000 0.5 126000
Scum pipes Scum pipes 100000 0 100000
Total 388000
Filter
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Underdrain
Leopold
Underdrain Type
S 1 ITT Water & Wastewater 60000 80000 0.5 84000
Media Sand 15m
3
U.S. Silica 100/m
3
1500 0 1500
Media Anthracite 24 m
3
U.S. Silica 100/m
3
2400 0 2400
Trough 1 Tetra Technologies 40000 0 40000
Total 128000
Disinfection System
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
System
Lamps/modules,
automatic level
controller,
intensity probe,
control system Trojan Technologies 620000 0 620000
Total 620000
Alum System
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Storage Tanks 2 General Alum & Chemical 100000 200000 0.4 208000
Solution Tank 1 100000
100000 0.4 104000
Total 312000
Digester
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Digester Heater BIO-HTX 1 Napier-Reid 500000 500000 0 500000
Sludge Pump
Peristaltic PD
Pump 4 Watson-Marlow Brendal 8000 32000 0 32000
Digester Check
Valve Diaphragm Valve 1 Red Valve 96000 96000 0 96000
Total 628000
Digester
Component Item Qty Vendor Unit Cost
($)
Subtotal
($)
Install
% Total ($)
Standby power
generator
Standby diesel
power generator
with outdoor
housing 1 100000 0 100000
Total 100000
MAJOR EQUIPMENT TOTALS: 2524000
Table 38: Concrete Cost Summary for Phase 1
Component
Number of
Components
Volume of
Component (m
3
) Unit Cost ($/yd
3
) Cost ($)
Primary Clarifier
Wall A 3 34.40 300 40,494
Wall B 4 8.60 300 13,498
Base 2 64.00 200 33,484
Baffle 2 2.13 600 3,348
Subtotal 90,824
Aeration Basin
Wall A 3 31.80 300 37,434
Wall B 4 52.00 300 81,616
Wall C 6 14.40 500 56,503
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Base 2 222.60 200 116,460
Subtotal 292,013
Secondary Clarifier
Wall A 2 24.46 300 19,197
Wall B 1 2.45 600 1,920
Wall C 1 24.46 300 9,599
Wall D 2 54.63 300 42,868
Base 1 259.90 200 67,987
Subtotal 141,571
Filter
Base 1 37.24 200 9,742
Head wall 1 13.10 300 5,140
Side walls 2 25.68 300 20,150
End wall 1 13.10 300 5,140
Weir 1 3.37 500 2,205
Influent Base 1 5.20 100 680
Subtotal 43,057
UV Channel
Head wall 2 0.14 600 216
Side walls 3 2.67 600 6,285
End wall 2 0.14 600 216
Subtotal 6,717
Digester
Digester 1 1 54.59 300 21,418
Digester 2 1 127.33 300 49,963
Base 1 1 50.27 200 13,149
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Base 2 + Roof 1 245.44 200 64,204
Subtotal 148,735
TOTAL 722,917
Table 39: Control and Instrumentation Cost Summary for Phase 1
Sludge Stabalization Control and Instrumentation
Code Description Manufacturer Model Num Capital ($) Install % Total ($)
I-1 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-13 Temperature
Indicator
Rosemount 664 TT
1 700 0.5 1050
I-19 High-Level
Alarm
RACO Verbatim
1 1000 0.5 1500
I-20 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-22 pH Indicator Rosemount Model 398 TUph 1 2000 0.5 3000
I-23 Level Indicator Siemens Sitrans Probe LR 1 3500 0.5 5250
I-24 Temperature
Indicator
Rosemount 664 TT
1 700 0.5 1050
I-25 High-Level
Alarm
RACO Verbatim
1 1000 0.5 1500
I-26 Pressure
Indicator
1 1000 0.5 1500
I-3 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-5 Level Indicator Siemens Sitrans Probe LR 1 3500 0.5 5250
I-6 pH Indicator Rosemount Model 398 TUph 1 2000 0.5 3000
I-7 Flow Meter ABB Aquamaster 1 5000 0.5 7500
PD-
1,2,3,4
Sludge Pump Watson-
Marlow
Brendal
Peristaltic PD Pump
1 18000 0.5 27000
CHOPX Sludge
Recirculation
Pump
Watson-
Marlow
Brendal
Centrifugal
1 18000 0.5 27000
V-1,2 Pressure
Release Valve
2 8000 0.2 19200
V-3,4 Sludge Pinch
Valve
Red Valve
2 900 0.2 2160
BP-1 Belt Press PACT DNYA BELT PRESS 1 200000 0.4 200000
MP-1 Metering Pump Hayward
Gordon
DMP
1 2000 0.5 3000
Totals 331460
Secondary Control and Instrumentation
Code Description Manufacturer Model Num Capital ($) Install % Total ($)
I-28
Dissolved
Oxygen Meter Danfoss EVITA Oxy 1 3000 0.4 4200
I-30
Dissolved
Oxygen Meter Danfoss EVITA Oxy 1 3000 0.4 4200
I-31
Dissolved
Oxygen Meter Danfoss EVITA Oxy 1 3000 0.4 4200
I-34
Pressure
Indicator -
Multi-Channel ABB N-AA 1 5000 0.4 7000
I-46
Pressure
Indicator -
Multi-Channel ABB N-AA 1 5000 0.4 7000
I-49 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-50
Dissolved
Oxygen Meter Danfoss EVITA Oxy 1 3000 0.4 4200
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
I-52 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-54 Flow Meter ABB Aquamater 1 5000 0.5 7500
I-56
Sludge density
meter 1 5000 0.4 7000
I-57
Suspended
Solids Meter Royce 7110/20 Continuous Series 1 5000 0.4 7000
I-58
Suspended
Solids Meter Royce 7110/20 Continuous Series 1 5000 0.4 7000
I-60 Sludge Level Cerlic CBX 1 5000 0 5000
PD-1,2 Sludge Pump
Watson-
Marlow
Brendal Peristaltic PD Pump 2 8000 0 16000
AB-1 Air pressurizer 4 8000 0 32000
I-84 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-53 Level Indicator Siemens Sitrans Probe LR 1 5000 0 5000
I-140 Alarm RACO Verbatim 1 1000 0.5 1500
MP-2,3 Metering Pump
Hayward
Gordon DMP 2 2000 0.5 6000
M-1 Mixer
Hayward
Gordon Top Entry Mixer 1 5000 0.5 7500
Total 130800
Tertiary Control and Instrumentation
Code Description Manufacturer Model Num Capital ($) Install % Total ($)
I-42 Level Indicator Siemens Sitrans Probe LR 1 5000 0 5000
I-44 Level Indicator Siemens Sitrans Probe LR 1 5000 0 5000
I-45 Level Indicator Siemens Sitrans Probe LR 1 5000 0 5000
I-61 Flow Indicator ABB Aquamaster 1 5000 0.5 7500
I-66 Flow Indicator ABB Aquamaster 1 5000 0.5 7500
I-72
UV Dosage
Indicator 1 0
I-73 UV Control 1 0
I-78 Flow Indicator ABB Aquamaster 1 5000 0.5 7500
I-83 Flow Indicator ABB Aquamaster 1 5000 0.5 7500
UV-
1/2/3 UV Banks Trojan UV3000 Plus 1 0
I-137 Flow Indicator ABB Aquamaster 1 5000 0.5 7500
I-131 Level Indicator Siemens Sitrans Probe LR 1 5000 0 5000
I-139 Flow Indicator ABB Aquamaster 1 5000 0.5 7500
I-133 Flow Indicator ABB Aquamaster 1 5000 0.5 7500
AB-1 Air Blower 1 10000 0.5 15000
CP-1
Centrifugal
Pump 1 8000 0 8000
Total 95500
Primary Control and Instrumentation
Code Description Manufacturer Model Num Capital ($) Install % Total ($)
I-100 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-101 Density Meter 1 2000 0.4 2800
I-105 Level Indicator Siemens Sitrans Probe LR 1 5000 0 5000
I-106 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-85
Sludge Level
Indicator Cerlic CBX 1 2000 0.4 2800
I-86 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-87 Density Meter 1 5000 0.4 7000
I-90
High-Level
Alarm RACO Verbatim 1 1000 0.5 1500
I-96 Level Indicator Siemens Sitrans Probe LR 1 5000 0 5000
I-97 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-98 Flow Meter ABB Aquamaster 1 5000 0.5 7500
I-99 Sludge Level Cerlic CBX 1 2000 0.4 2800
Total 130800
PLCs and SCADA Interfacing Costs
Code Description Manufacturer Model Num Capital ($) Install % Total ($)
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Local PLCs Allen-Bradley SLC 5/05 10 2900 0.4 40600
Motor Control
Center GE 1 10000 0.5 15000
SCADA Wiring
and Interfacing 1 15000
Total 70600
CONTROL & INSTRUMENTATION TOTALS: 716760
Table 40: Project Capital Cost Summary for Phase 1 Expansion
Parameter
% of Equipment
Cost Cost ($)
Equipment Cost + Concrete Cost + Control
and Instrumentation 120 3,963,677
Equipment Installation 50 1,651,532
Process mechanical piping 65 2,146,992
Electrical 10 330,306
Buildings 20 660,613
Yard Improvements 10 330,306
Service Facilities 70 2,312,145
Engineering and Supervision 35 1,156,073
Project Management and Overhead 40 1,321,226
SUBTOTAL EQUIPMENT COSTS 80 13,872,870
Misc. and unidentified equipment 10 1,734,109
Misc. and unidentified process mechanical 5 867,054
Misc. and unidentified electrical / I&C 5 867,054
TOTAL EQUIPMENT COSTS 65 17,341,088
Retrofit and Demolition 5 867,054
Contractor Overhead and Profit 20 3,641,628
Market and Construction Contingency 10 2,184,977
TOTAL PROJECT COSTS 24,034,747
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
The capital cost estimation for Phase 2 of the expansion was conducted in a similar manner as
Phase 1, using similar values and adjusting quantities based on the conceptual design. The total
project costs for Phase 2 are shown in Table 41.
Table 41: Project Capital Cost Summary for Phase 2 Expansion
Parameter
% of Equipment
Cost Cost ($)
Equipment + Concrete + Control and
Instrumentation 120 1,673,157
Equipment Installation 50 697,149
Process mechanical piping 65 906,293
Electrical 10 139,430
Buildings 20 278,859
Yard Improvements 10 139,430
Service Facilities 70 976,008
Engineering and Supervision 35 488,004
Project Management and Overhead 40 557,719
SUBTOTAL EQUIPMENT COSTS 80 5,856,049
Misc. and unidentified equipment 10 732,006
Misc. and unidentified process mechanical 5 366,003
Misc. and unidentified electrical / I&C 5 366,003
TOTAL EQUIPMENT COSTS 50 7,320,062
Retrofit and Demolition 10 732,006
Contractor Overhead and Profit 20 1,610,414
Market and Construction Contingency 20 1,932,496
TOTAL PROJECT COSTS 11,594,978
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
E.2 Operations and Maintenance
The operations and maintenance costs of the Acton WWTP Phase 1 Expansion are estimated at
$3.4 million per year. This is divided into:
Manpower (i.e. labourors, lab testers and supervisors)
Electrical power (i.e. lighting, SCADA system and other instrumentation)
Chemicals (i.e. alum dosing, polymer addition)
Waste transport and disposal (transportation to and storage before agricultural
application)
Maintenance (i.e. repairing, painting, cleaning and replacing parts).
The estimations were taken from an operations cost for the Juan Diaz WWTP which operates in
a similar manner to the proposed Acton WWTP (Hazen and Sawyer Environmental Engineers
and Scientists, 2003). The scaling from the Juan Diaz WWTP to Actons predicted flow was
calculated with the following equation:
ActonWWTPvalue
OtherWWTPvalue
=
OtherWWTPcapacity
0.6
ActonWWTPcapacity
where capacities were based on average daily flowrates.
The 2021 prediction is expected to be increased at 4% a year according to the Engineering
News-Record Construction index (Engineering News-Record, 2011).
Direction from our faculty advisor and consultant advisor indicated that a typical rule of thumb
for annual operations and maintenance costs should be approximately $0.35/day per m
3
/day of
flow for a small-to-medium sized plant with conventional activated sludge and tertiary
treatment. This rule of thumb was used to scale the annual operations and cost estimate, while
maintaining the cost category distribution from Juan Diaz WWTP (Hazen and Sawyer
Environmental Engineers and Scientists, 2003).
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
APPENDIX F MANUFACTURER SPECIFICATION
SHEETS
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Watson-Marlow Brendal
Peristaltic PD Pump
United States of America
Telephone 800 282 8823
Fax: 978 658 0041
Email
support@wmbpumps.com
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
CHOPX Chopper Pumps
HAYWARD GORDON
Solids Handling Pumps
6660 Campobello Rd, Mississauga,
Ontario
L5N 2L9
Tel: (905) 567-6116 Fax: (905) 567-1706
www.haywardgordon.com
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Stamford Scientific International
Standard 9" Disc - AFD270
Fine Bubble Disc Diffusers
Stamford Scientific International, Inc.
4 Tucker Drive,
Poughkeepsie, NY 12603 USA.
Tel: +1- 845-454-8171
Fax: +1- 845-454-8094
email: info@stamfordscientific.com
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
PACT
BELT PRESS WITH GRAVITY
THICKENER
PACT WATER & WASTEWATER TREATMENT EQUIPMENT
65 Huaqing Road, Huazhuang Town, Binhu District, Wuxi
City,
Jiangsu Province, China 214131
Tel+86-510-8560 1186
Fax+86-510-8560 8396
www.pact-tont.com
info@pact-tont.com
Hayward Gordon
Polymer & Chemical Feed Systems
TORONTO (HEAD OFFICE)
5 Brigden Gate
Halton Hills ON L7G 0A3
T: (905) 693-8595
F: (905) 693-1452
info@haywardgordon.com
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Trojan
UV3000plus
Head Office (Canada)
3020 Gore Road
London, Ontario, Canada N5V 4T7
Telephone: (519) 457-3400
Fax: (519) 457-3030
www.trojanuv.com
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Caterpillar
D I E S E L G E N E R A T O R SE
T
TOROMONT CAT
290 INDUSTRIAL RD
CAMBRIDGE ONTARIO, N3H 4R7
Phone numbers: 1 519 650-1211
GENERAL INFO
1 519 650-1372 GENERAL INFO (FAX)
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
APPENDIX G DESIGN CALCULATIONS
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
G.1 ASSUMPTIONS
Calculations for the sizing of the components have been included in an Excel spreadsheet. The
equations used for each calculation step are written in the Notes section of the spreadsheet.
Assumptions for values are also written in this spreadsheet. Assumptions that are very
important and/or require further explanation are included in this section.
G.1.1 Primary Clarifier
Pertinent assumptions made for the primary clarifier include:
Solid content are 2% with a specific gravity of 2.6 and diameter of 0.0001m.
BOD concentrations returning from digester and sludge drying belt are negligible in
comparison to the BOD concentrations from raw sewage.
Inflows are raw sewage flow from grit chamber, supernatant flow from digester and belt
press filtrate.
Inflow to the existing tanks and new tanks are governed by volume proportions (i.e. the
new tanks get more flow than the existing tanks).
G.1.2 Aeration Tank
Pertinent assumptions made for the activated-sludge system include:
Design at 10C will suffice, as this is the upper bound for water temperature range
provided, and therefore represents the lowest dissolved oxygen conditions the tank will
experience.
A conservative value of 4000 mg/L for the MLSS in the aeration basin.
NO
x
percentage of 80%.
Percent oxygen concentration leaving the aeration tank is 19%.
Residual alkalinity concentration required to maintain a pH of 6.8 to 7.0 is 80 g/m
3
as
CaCO
3
.
Assumed zero salinity of influent water.
The return sludge mass concentration is 8000 g/m
3
, due to the assumption that the
sludge is moderate settling/thickening.
The hydraulic application rate at average flow for secondary clarifier is 22 m
3
/m
2
d,
which is within the range of 16 to 28 (Table 8-7, Metcalf & Eddy, 2003).
G.1.3 Secondary Clarifier
Pertinent assumptions made for the secondary clarifier include:
The Solids Flux Analysis approach sufficiently applies to the sizing of the secondary
clarifier for this facility.
The graph used to produce the solids flux curve is based off of a text example (Henze,
van Loosdrecht, Ekama, & Brdjanovic, 2008), however it is assumed that it applies for
the preliminary design of this plant expansion. This graph is shown below in Figure 9.
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Calculated clarifier depth was found to 2.45 m, however Design Guidelines for Sewage
Works recommend a depth between 3.6 and 4.6 m therefore 4 m was chosen.
Figure 9: Hindered settling Solids Flux Curve used for Secondary Clarifier Sizing
G.1.4 Phosphorus Removal
Filtration assumptions include:
Filter is sized for a temperature of 5C although it is housed indoors for a worst case
scenario.
The existing filters are sized to handle 75% of the current maximum day flow each so one
additional filter should be adequate to handle the additional flow.
The water entering the filtration system is fairly clean and thus backwash for the proposed
filter occurs once every two days.
The time required to fill the backwash tank with one backwash water volume is 30 minutes.
Alum dosing assumptions include:
The design alum dose should be the historical dosage in which that dosage or less was
delivered 95% of the time (see Figure 10).
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Figure 10: Plant B Alum Dose Determination
Liquid alum can be stored for 28 days without degradation in quality. Storage for at least
28 days is preferred.
The existing plant has enough alum storage space and vessels for half of the required
amount of alum, as well as one existing solution tank.
Wastewater characteristics will remain similar for future flows.
G.1.5 UV System
The UV system was designed with the following assumptions:
The UV system was sized with 3 channels for the entire plant. The existing plant has
only one operational channel.
The minimum UV transmittance and design dose were selected based from guidelines,
but pilot tests must be run to determine the true requirements.
G.1.6 Anaerobic Digester
Pertinent assumptions made for the digester include:
With proper digester instrumentation, the digesters will be constantly fed and ensure
the digester is always seeded with sufficient microbes for digestion.
The incoming solids have an OM content of 85%. 15% is inert.
Destroyed OM is 55%.
Methane is about 70% of biogas from efficiency of dual-digester.
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
G.1.7 Hydraulics
Hydraulics assumptions include:
The proposed system ties into the existing outfall.
Pipe diameters do not change on either side of valves, thus head loss through valves is
minimal.
Baffles could be represented as orifices.
Piping follows the Phase 1 expansion piping layout.
There is no head loss in the clarifiers.
The aeration basin can be modeled as open channel flow. Head loss due to aeration was
neglected.
G.1.8 Electrical Upgrade
Energy costs have been estimated from 2.2MJ/m3 4.8MJ/m
3
for typical WWTPs (Baruth,
2010). Assuming this plant operates on the upper end of that range, increased peak flow energy
requirements were calculated as 4.8MJ /m
3
times the difference in peak flow requirements.
Q= Q
phase1
Q
current
=
1545m
3
d
P =
4.8MJ
m
3
1545m
3
d
0.01157kW
MJ
d
= 85kW
150kW was chosen for safety factor and to account for future expansion in Phase 2.
G.2 Design Equations
The governing equation used for the design of the Acton WWTP expansion was the standard
mass balance:
Through manipulation of this equation, each element of the treatment plant has been designed.
The objective of the design is to ensure the mass coming in will equal the mass going out.
Effective and efficient treatment plants should not accumulate mass.
Empirical equations were used to size some components including the secondary treatment,
secondary clarifier (also with use of a settling curve) and anaerobic digester. These equations
have been taken from Metcalf and Eddy (2003).
Appendix B verifies the values entered into the equations based on assumptions, guidelines, and
other justifications made throughout the report. One of the most important criteria is to ensure
the plant expansion will be compatible with the existing plant. The exact use of each equation
used below can be seen in the Excel spreadsheets in Appendix G.
Holding tanks, such as the clarifiers, have been designed based on appropriate retention times.
The volume, V, was based on the hydraulic retention time, HRT, and flow, Q.
Acton Wastewater Treatment Plant Design Report WEF Student Design Competition 2011
Mass balance and volumetric flow of the sludge through the pumps were determined using
density calculations.
Where is density; P is percent; and S is specific gravity.
BOD inflow to the clarifier is calculated through a mass flow balance based on flow from the
supernatant of the digester and inflow to the facility.
The flow required for calculation of pipe sizing, were equated with the volumetric flow
equation.
Where Q is volumetric flow; A is cross-sectional area; and v is the velocity through the pipe.
G.3 Factors of Safety
Factors of safety and design flows were used throughout component design to account for
emergencies. These values and design flows were based on the MOEs Design Guidelines for
Sewage Works, the facility was designed for peak hour or maximum day flows.
G.4 Calculation Spreadsheets
The following spreadsheets show the detailed design calculations.
Primary Sludge
4,221 kg/d
Primary
Sedimentation
Influent
10,000,080 kg/d
Secondary Sludge
176,953 kg/d
Raw Sewage
Solid Waste
Holding Tank
Secondary Digester
Land Application
Boiler
Heat Back to Plant
Primary Digester
Black Creek
Effluent
Secondary
Sedimentation
Deep Bed
Filter
RAS
WAS
Activated Sludge
Alum
Polymer
Digester Loading
181,174 kg/d
To Press
96,621 kg/d
UV
Treatment
Centrate
9,740 kg/d Supernatant
84,821 kg/d
Waste water
Alum
Sludge
Solid Waste
Biogas
Heat
Belt Press
Compressed
Air
Alum/Polymer Treatment
Compressed Air
Screening Grit Removal
Backwash Inputs Outputs
1
1 1
1
03/21/2011 1 Adam Erb
Adam Erb
Adam Erb
21/03/11
2
1 1
Phase 1
PFD
Alexandra Chan
SLIT
I-85
FIT
I-86
dIT
I-87
I-88
FC
I-89
LSHL
I-90
KC
I-91
HS
I-92
Hand/Off/Auto
HS
I-93
SL
HS
I-94
Delay
HS
I-95
FR
LIT
I-96
FIT
I-97
Digester
Activated Sludge
FIT
I-98
SLIT
I-99
FIT
I-100
dIT
I-101
I-102
FC
I-103
KC
I-104
LIT
I-105
FIT
I-106
Return fromDigester
Influent
Return fromFilter
Code Description Manufacturer Model Type I/O
I-100 Flow Meter ABB Aquamaster FIT I
I-101 dIT I
I-102 Logic Description
I-103 Flow Control FC O
I-104 Timer Allen-Bradley 700-FE KC O
I-105 Level Indicator Siemens Sitrans Probe LR LIT I
I-106 Flow Meter ABB Aquamaster FIT I
I-85 Sludge Level Indicator Cerlic CBX SLIT I
I-86 Flow Meter ABB Aquamaster FIT I
I-87 Density Meter dIT I
I-88 Logic Description
I-89 Flow Control FC O
I-90 High-Level Alarm RACO Verbatim LSHL O
I-91 Timer Allen-Bradley 700-FE KC O
I-92 Hand/Off/Auto HS I
I-93 Slude Level Setpoint HS I
I-94 Pumping Delay HS I
I-95 Flow Rate HS I
I-96 Level Indicator Siemens Sitrans Probe LR LIT I
I-97 Flow Meter ABB Aquamaster FIT I
I-98 Flow Meter ABB Aquamaster FIT I
I-99 Sludge Level Cerlic CBX SLIT I
Control Logic
I-88 and I-102
If Sludge_Blanket_Height > Setpoint
Set Pump 50%
If SDI > 2.5
Set Pump 0%
Set Alarm
Time_Delay()
Control Strategy
WW train
4-20ma signal
Sludge train
Steam
1
1 1
1
03/21/2011 1 Adam Erb
Adam Erb
Adam Erb
21/03/11
9a
4 1
Phase 1 P&ID
Primary Treatment
Alexandra Chan
PIT
I-46
FIT
I-49
DOIT
I-50
FIT
I-52
FIT
I-54
FC
I-55
dIT
I-56
TSS
I-57
TSS
I-58
KC
I-59
Filter
Primary
Digester
SLIT
I-60
DOIT
I-28
I-29
DOIT
I-30
DOIT
I-31
I-32
I-33
PIC
I-34
AB-1/1b
HC
I-35
DO setpoints
HC
I-37
Recycle Ratio
HC
I-38
Wasting Flowrate
HC
I-39
Pump Timing
PD-1
PD-1b
PD-2/2b
Code Description Manufacturer Model Type
I-28 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-29 Logic Description # # #
I-30 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-31 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-32 Logic Description # # #
I-33 Logic Description # # #
I-34 Pressure Indicator - Multi-Channel ABB N-AA PIC
I-35 Hand DO Setpoint HC
I-37 Hand RAS Ratio HC
I-38 Hand Wasting Flowrate HC
I-39 Hand Wasting Timing HC
I-46 Pressure Indicator - Multi-Channel ABB N-AA PIT
I-49 Flow Meter ABB Aquamaster FIT
I-50 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-52 Flow Meter ABB Aquamaster FIT
I-54 Flow Meter ABB Aquamater FIT
I-55 Flow Control FC
I-56 Sludge density meter dIT
I-57 Suspended Solids Meter Royce 7110/20 Continuous Series TSS
I-58 Suspended Solids Meter Royce 7110/20 Continuous Series TSS
I-59 Timing Function # # KC
I-60 Sludge Level Cerlic CBX SLIT
PD-1,2 Sludge Pump Watson-Marlow Brendal Perisatalic PDPump
AB-1 Air pressurizer
I-111 Timing Function KC
I-84 Flow Meter ABB Aquamaster FC
I-53 Level Indicator Siemens Sitrans Probe LR LT
I-51 Logic Description # # #
I-140 Alarm RACO Verbatim DHL
MP-2,3 Metering Pump Hayward Gordon DIAPHRAGM METERING PUMPS
M-1 Mixer Hayward Gordon Top Entry Mxier
MP-2
M
-1
MP-3
KC
I-111 FC
I-84
LT
I-53
I-51
Alum
FC
I-112
DHL
I-140
Control Logic
I-14
If Sludge_density < max_density
Set Sludge_flow = Influnt_flow*Ratio
else
Alarm
I-32 & I-33
Feedforward-PI control for aeartion DO levels using cascading control sheme.
I-32 meausures tank DO against setpoint and generates error signal for I-33
I-33 controls pressure against set point by adjusting actuated valve.
I-51
Load mixing tank with alum, mixfor period K, after K pump to aeration tank.
RAS
WAS
Control Strategy
WW train
4-20ma signal
Sludge train
Steam
1
1 1
1
03/21/2011 1 Adam Erb
Adam Erb
Adam Erb
21/03/11
9b
4 2
Phase 1 P&ID
Secondary Treatment
Alexandra Chan
DOIT
I-293
FIT
I-61
FC
I-62
HC
I-63
HS
I-64
I-65
ON/OFF
A/M
FIT
I-66
FC
I-67
HC
I-68
HS
I-69
I-70
ON/OFF
A/M
UV-1/2/3
FC
I-71
UVDIT
I-72
UVC
I-73
HC
I-74
MC
I-75
I-76
KC
I-77
FIT
I-78
FC
I-79
HC
I-80
HS
I-81
I-82
ON/OFF
A/M
FIT
I-83
LC
I-40
LIT
I-42
LC
I-43
LIT
I-44
LC
I-47
LIT
I-45
I-48
Effluent
Code Description Manufacturer Model Type I/O
I-40 Level Control # # LC O
I-42 Level Indicator Siemens Sitrans Probe LR LIT I
I-43 Level Control # # LC O
I-44 Level Indicator Siemens Sitrans Probe LR LIT I
I-45 Level Indicator Siemens Sitrans Probe LR LIT I
I-47 Level Control # # LC O
I-61 Flow Indicator ABB Aquamaster FIT I
I-62 Flow Control # # FC O
I-63 Hand Mix Select # # HC I
I-64 Hand Auto/Manual # # HS I
I-66 Flow Indicator ABB Aquamaster FIT I
I-67 Flow Control FC O
I-68 Hand Manual Mix Select HC I
I-69 Hand Auto/Manual HS I
I-71 Flow Control # # FC O
I-72 UV Dosage Indicator UVDIT I
I-73 UV Control UVC I
I-74 Hand Manual Mix Select # # HC I
I-75 Hand Auto/Manual # # MC I
I-77 Timer Function # # KC O
I-78 Flow Indicator ABB Aquamaster FIT I
I-79 Flow Control # # FC O
I-80 Hand Manual Mix Select # # HC I
I-81 Hand Auto/Manual # # HS I
I-83 Flow Indicator ABB Aquamaster FIT I
UV-1/2/3 UV Banks Trojan UV3000 Plus O
I-137 Flow Indicator ABB Aquamaster FIT I
I-130 Logic Description
I-131 Level Indicator Level Indicator Siemens Sitrans Probe LR LIT
I-139 Flow Indicator ABB Aquamaster FIT I
I-136 Flow Control
I-135 Flow Control
I-129 Flow Control
I-138 Flow Control
I-132 Flow Control
I-134 Flow Control
I-133 Flow Indicator ABB Aquamaster FIT I
AB-1 Air Blower
CP-1 Centifruegal Pump
AS Effluent
FC
I-137
LIT
I-131
I-130
FIT
I-139
FC
I-136
FC
I-135
AB-1
FC
I-132
CP-1
Backwash
FC
I-129
Back to Inlet Works
FIT
I-133
FC
I-134
FC
I-138
Control Logic
I-48
If I-29 > 8000 L/m
Open I-22, I-11,I-2
Else If I-29 > 5000 L/m
Open I-22, I-11
Close I-2
Else
Open I-22
Close I-11, I-2
I-130
If water level is below maximum continue loading.
Periodically close inlet and backwash at interval K.
Control Strategy
WW train
4-20ma signal
Sludge train
Steam
1
1 1
1
03/21/2011 1 Adam Erb
Adam Erb
Adam Erb
21/03/11
9c
4 3
Phase 1 P&ID
Tertiary Treatment
Alexandra Chan
FIT
I-1
FC
I-2
FIT
I-3
FC
I-4
LIT
I-5
PHIT
I-6
V-4
V-3
PD-1
PD-2
PD-4
FIT
I-7 FC
I-8
KC
I-9
HC
I-10
HC
I-11
PD-3
HS
I-12
Timing
ON/OFF
A/M
TIT
I-13
I-14
I-15
I-16
HC
I-17
Setpoint
TC
I-18
LSHL
I-19
FIT
I-20
FC
I-21
PHIT
I-22
LIT
I-23
TIT
I-24
LSHL
I-25
V-1
PIT
I-26
FC
I-27
Gas Infastructure Boiler Hot Water
Sludge fromAS
Sludge from
Clarifier
Primary
V-2
Current
Digesters
Stage1 Additon
CHOPX
Code Description Manufacturer Model Type I/O
I-1 Flow Meter ABB Aquamaster FIT I
I-10 Mixer Timing Hand Select # # HC I
I-11 Manual Mix Select # # HC I
I-12 Auto/Manual # # HS I
I-13 Temperature Indicator Rosemount 664 TT TIT I
I-14 Logic Description # #
I-15 Logic Description # #
I-16 Logic Description # #
I-17 Setpoint Temp # # HC I
I-18 Temp Control TC O
I-19 High-Level Alarm RACO Verbatim LSHL O
I-2 Flow Control FC O
I-20 Flow Meter ABB Aquamaster FIT I
I-21 Flow Control FC O
I-22 pH Indicator RosemountModle 398 TUph PHIT I
I-23 Level Indicator Siemens Sitrans Probe LR LIT I
I-24 Temperature Indicator Rosemount 664 TT TIT I
I-25 High-Level Alarm RACO Verbatim LSHL O
I-26 Pressure Indicator PIT I
I-27 Flow Control # # FC O
I-3 Flow Meter ABB Aquamaster FIT I
I-4 Flow Control # # FC O
I-5 Level Indicator Siemens Sitrans Probe LR LIT I
I-6 pH Indicator RosemountModle 398 TUph PHIT I
I-7 Flow Meter ABB Aquamaster FIT I
I-8 Flow Control # # FC O
I-9 Timer Function # # KC O
PD-1,2,3,4 Sludge Pump Watson-Marlow Brendal Perisatalic PDPump O
CHOPX Sludge Recirculation Pump Watson-Marlow Brendal Centrifugal O
V-1,2 Pressure Release Valve O
V-3,4 Sludge Pinch Valve Red Valve O
BP-1 Belt Press PACT DNYA BELT PRESS O
MP-1 Metering Pump Hayward Gordon DIAPHRAGM METERING PUMPS O
PD-1b
PD-2b
CHOPXb
PD-3b
PD-4b
1
1 1
1
BP-1
Belt Press Filter
MP-1
Polymer Tank
Stage1 Additon
Land Application
Control Logic
I-14
If sludge in is available feed digester 1 for period K, and close
digester 2 valve. When K timing is up feed digester 2 and close
digester 1 valve for period K. Totalize both digester sludge inputs
to keep track of loading.
I-15
If level is below maximum, ph is within threshold, continue regular
process and circulate sludge, else sound alarm.
I-16
PI temperature algorithm
Control Strategy
WW train
4-20ma signal
Sludge train
Steam
03/21/2011 1 Adam Erb
Adam Erb Alexandra Chan
Adam Erb
21/03/11
9d
4 4
Phase 1 P&ID
Sludge Treatment
Raw Sewage
Solid Waste
Secondary Digester
Land Application
Boiler
Heat Back to Plant
Primary Digester
Black Creek
Effluent
Secondary
Sedimentation
Primary
Sedimentation
Deep Bed
Filter
RAS
WAS
Alum
Polymer
UV
Treatment
Belt Press
Compressed
Air
Screening
Grit Removal
Activated
Sludge
with BNR
A
n
a
e
ro
b
ic
A
n
o
x
ic
A
e
ro
b
ic
Waste water
Alum
Sludge
Solid Waste
Biogas
Heat
Alum/Polymer Treatment
Compressed Air
1
1 1
1
03/21/2011 1 Adam Erb
Adam Erb
Adam Erb
21/03/11
12
1 1
Phase 2
PFD
Alexandra Chan
Inputs Outputs
PIT
I-267
FIT
I-266
DOIT
I-277
FIT
I-272
FIT
I-287
FC
I-279
dIT
I-264
TSS
I-274
TSS
I-275
KC
I-280
Filter
Primary
Digester
SLIT
I-282
DOIT
I-289
I-278
DOIT
I-276
I-268
I-290
PIC
I-292
HC
I-270
DO setpoints
HC
I-288
Recycle Ratio
HC
I-284
Wasting Flowrate
HC
I-269
Pump Timing
Code Description Manufacturer Model Type
I-28 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-29 Logic Description # # #
I-30 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-31 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-32 Logic Description # # #
I-33 Logic Description # # #
I-34 Pressure Indicator - Multi-Channel ABB N-AA PIC
I-35 Hand DO Setpoint HC
I-37 Hand RAS Ratio HC
I-38 Hand Wasting Flowrate HC
I-39 Hand Wasting Timing HC
I-46 Pressure Indicator - Multi-Channel ABB N-AA PIT
I-49 Flow Meter ABB Aquamaster FIT
I-50 Dissolved Oxygen Meter Danfoss EVITA Oxy DOIT
I-52 Flow Meter ABB Aquamaster FIT
I-54 Flow Meter ABB Aquamater FIT
I-55 Flow Control FC
I-56 Sludge density meter dIT
I-57 Suspended Solids Meter Royce 7110/20 Continuous Series TSS
I-58 Suspended Solids Meter Royce 7110/20 Continuous Series TSS
I-59 Timing Function # # KC
I-60 Sludge Level Cerlic CBX SLIT
PD-1,2 Sludge Pump Watson-Marlow Brendal Perisatalic PD Pump
AB-1 Air pressurizer
I-111 Timing Function KC
I-84 Flow Meter ABB Aquamaster FC
I-53 Level Indicator Siemens Sitrans Probe LR LT
I-51 Logic Description # # #
I-140 Alarm RACO Verbatim DHL
MP-2,3 Metering Pump Hayward Gordon DIAPHRAGM METERING PUMPS
M-1 Mixer Hayward Gordon Top Entry Mxier
CP-5 Internal Recycle Pump
M-2 Anearobic Phase Mixer
M
-1
KC
I-285 FC
I-265
LT
I-283
I-271
Alum
FC
I-281
DHL
I-273
RAS
WAS
I-291
Control Strategy
WW train
4-20ma signal
Sludge train
Steam
1
1 1
1
03/21/2011 1 Adam Erb
Adam Erb
Adam Erb
21/03/11
13
1 1
Phase 2 P&ID
Changes
Alexandra Chan
A
n
a
e
r
o
b
ic
A
n
o
x
ic
CP-5
Internal Recycle
M-2